Automated Manufacturing Systems

Julin Proenza.
University of the Balearic Islands. SPAIN

Julin Proenza. UIB. Mar 2009

The aim of this presentation

Introduce the basics of Automated Manufacturing Systems
(AMSs)
Provide a general picture of the organization of these
systems
Show how AMSs integrate multiple kinds of subsystems
and therefore require multiple kinds of techniques for their
design
Introduce the different levels of control present in AMSs
Make evident the importance of the communication
subsystems for this kind of system
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Julin Proenza. UIB. Mar 2009

Presentation Outline
1. Introduction
2. Components
3. Organization
1. General aspects
2. Types of Control

4. Reference Models. The CIM model

5. Design Approaches (centralized vs. distributed system)
6. Control Networks in AMSs
1.
2.
3.
4.
3

The OSI model point of view

The control hierarchy point of view
The device hierarchy point of view
Communication network architecture

Julin Proenza. UIB. Mar 2009

Presentation Outline
1. Introduction
2. Components
3. Organization
1. General aspects
2. Types of Control

4. Reference Models. The CIM model

5. Design Approaches (centralized vs. distributed system)
6. Control Networks in AMSs
1.
2.
3.
4.
4

The OSI model point of view

The control hierarchy point of view
The device hierarchy point of view
Communication network architecture

Julin Proenza. UIB. Mar 2009

Introduction (1)
Competition among manufacturing companies together
with the availability of adequate computing and
communication technology has caused dramatic
changes in the manufacturing environment
From manual operation to semiautomatic operation
(machines able to perform several steps of an automated
sequence) and from there to fully automated facilities
Other terms used to denote these systems are:
FMS: Flexible Manufacturing Systems
FOF: Factory of the Future
CIM: Computer Integrated Manufacturing (comprising also the
other companys activities such as marketing, finances, etc.)
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Julin Proenza. UIB. Mar 2009

Introduction (2)
Definition of AMS: A system consisting of a set of
interconnected stations for material processing that are
capable of automatically processing a wide variety of
types of pieces simultaneously and controlled by
computers
Characteristics of the automated manufacturing:
High degree of automation
High degree of integration
High degree of flexibility
Flexibility in the production volume
Flexibility in the routing
Flexibility at the product level
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Julin Proenza. UIB. Mar 2009

Introduction (3)
Advantages of automated manufacturing when
compared with traditional manufacturing:

Productivity increase
Reduced lead times
Reduced labour costs
More efficient use of equipment
Improved product quality

Julin Proenza. UIB. Mar 2009

Presentation Outline
1. Introduction
2. Components
3. Organization
1. General aspects
2. Types of Control

4. Reference Models. The CIM model

5. Design Approaches (centralized vs. distributed system)
6. Control Networks in AMSs
1.
2.
3.
4.
8

The OSI model point of view

The control hierarchy point of view
The device hierarchy point of view
Communication network architecture

Julin Proenza. UIB. Mar 2009

Components (1)
We are going to focus on the elements that are directly
involved in the physical manufacturing (since AMSs
are usually considered to take care also of other aspects
such as marketing, finances, etc.)
Sensors
Sensors of pressure, temperature, position, speed, etc.
Limit switches

Actuators
E.g. Electro-valves, relays, etc.
Actuated equipment
Pneumatic
Hydraulic
Electro-mechanic

Julin Proenza. UIB. Mar 2009

Components (2)
Industrial robots: programmable mechanical manipulator (arm)
capable of moving along several directions describing complex
trajectories with its end-effector (the device that is attached to the
end of the arm). It is designed to carry out factory work usually
performed by human workers.

Complex manipulation of pieces

Spray painting
Inspection
Assembly

Computerized Numerical Control (CNC) equipment:

Computerized machine tool whose actions are controlled by
directly inserting numerical data
Drill
Milling Machine
Lathe
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Julin Proenza. UIB. Mar 2009

Components (3)
Programmable Logic Controllers (PLCs): Solid state devices
used for controlling the operation of machines or processes by
means of a stored program and the feedback of the I/O devices
Implementation of sequential processes.
GRAFCETs are used to specify the processes.
Ladder diagrams are used as programming language
Scan: periodic cycle in which inputs are read, new state is computed
and outputs are updated.
Choice of a PLC: scan time, number of I/O both digital and analog,
communication interface, memory size, supply voltage, programming
language, etc.

Transfer systems

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Automated Guided Vehicles (AGVs)

Towline Systems
Roller Conveyor Systems
Belt Conveyor Systems

Julin Proenza. UIB. Mar 2009

Components (4)
Automated Warehouses: systems that control the movement of
materials and send the corresponding information to the
adequate computers within the factory
A.K.A.: Automated Storage/Retrieval Systems (AS/RS)
Functions and advantages:

Status and location of materials is controlled by computers

Inventory is simplified
Security and safety are improved
Unnecessary movements of materials are eliminated

Bar code readers (as those used in supermarkets)

Uses (mainly identification and thereby):
Tracking of components in an assembly
Correct assembly verification

Advantages:
Easy installation and interface with a computer (COTS comp. available)
Low cost
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Julin Proenza. UIB. Mar 2009

Components (5)
Vision Systems:
Uses (generally test and inspection):
Localization of objects and their absence
Identification of objects
Dimensional gauging

Types of output information:

Logical data (resulting from image processing)
Video information (e.g. in security applications)

Microcontrollers:
Play similar roles as the PLCs
Differences:

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(initially) They are faster and have better capacity for data manipulation
Less I/O ports
More programming languages
Easier interface with other computers

Computers: (higher-level control and database management)

Julin Proenza. UIB. Mar 2009

Presentation Outline
1. Introduction
2. Components
3. Organization
1. General aspects
2. Types of Control

4. Reference Models. The CIM model

5. Design Approaches (centralized vs. distributed system)
6. Control Networks in AMSs
1.
2.
3.
4.
14

The OSI model point of view

The control hierarchy point of view
The device hierarchy point of view
Communication network architecture

Julin Proenza. UIB. Mar 2009

Organization (1)
Let us discuss how these elements are organized
An illustrative concept is the manufacturing cell

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Julin Proenza. UIB. Mar 2009

Organization (2)
A factory can be seen as a set of manufacturing cells
Many technological areas are involved in an AMS:

Mechanical Engineering
Computing and Communications
Control
Robotics
Vision & Perception Systems
Computer Aided Design (CAD)
Computer Aided Manufacturing (CAM)
Computer Aided Test (CAT), etc.

We are going to focus now on those directly involved in

the physical manufacturing process
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Julin Proenza. UIB. Mar 2009

Organization (3)
One of those technologies is Control:
The methodology used to alter the behaviour or the performance
of a system according to a predetermined goal.

In an AMS there are several types of control

(depending on the abstraction level)
Dynamic Control:
Lowest level
Directly controls the process variables
E.g. position of a robotic arm

Sequential Control
A process is sequenced as a series of steps (binary actuation or DC)
Typically performed by PLCs

Supervisory Control
System-wide Control
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Julin Proenza. UIB. Mar 2009

Organization (4)
In an AMS there are several types of control (depending
on the abstraction level)
Dynamic Control:
Lowest level
Directly controls the process variables
E.g. position of a robotic arm

Input
(reference)

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Error
-

Controller

System to be
controlled

Output

Julin Proenza. UIB. Mar 2009

Organization (5)
In an AMS there are several types of control (depending
on the abstraction level)
Sequential
Control
A process
sequenced
as a series
of steps
Typically
performed
by PLCs

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Julin Proenza. UIB. Mar 2009

Presentation Outline
1. Introduction
2. Components
3. Organization
1. General aspects
2. Types of Control

4. Reference Models. The CIM model

5. Design Approaches (centralized vs. distributed system)
6. Control Networks in AMSs
1.
2.
3.
4.
20

The OSI model point of view

The control hierarchy point of view
The device hierarchy point of view
Communication network architecture

Julin Proenza. UIB. Mar 2009

Reference Models (1)

Different approaches are possible
From the point of view of materials & information flow

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Julin Proenza. UIB. Mar 2009

Reference Models (2)

From the point of view of the databases

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Julin Proenza. UIB. Mar 2009

The (hierarchical) CIM Model

The model ISO-RM-FA covers the company as a whole
Company:

Corporate management

Factory:

Manufacturing planning

Shop:

Assignment and Supervision of Materials and Resources

Cell Pool: Coordination of Machines and Operations. Alarms & Monitoring

Cell:

Machine Control. Execution of manufacturing commands

Machine: Activation of sequences and movements. Physical manufacture

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Julin Proenza. UIB. Mar 2009

Presentation Outline
1. Introduction
2. Components
3. Organization
1. General aspects
2. Types of Control

4. Reference Models. The CIM model

5. Design Approaches (centralized vs. distributed system)
6. Control Networks in AMSs
1.
2.
3.
4.
24

The OSI model point of view

The control hierarchy point of view
The device hierarchy point of view
Communication network architecture

Julin Proenza. UIB. Mar 2009

Design Approaches
Two approaches could be considered (only one is possible)
Centralized approach:
Distributed approach:

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Julin Proenza. UIB. Mar 2009

Design Approaches
Two approaches could be considered (only one is possible)
Centralized approach:
Pros:
Effective for small systems
Easy programming and maintenance

Cons:
Reduced capacity and flexibility
Single point of failure
Not adequate for real (complex) AMSs

Distributed approach:
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Julin Proenza. UIB. Mar 2009

Design Approaches
Two approaches could be considered (only one is possible)
Centralized approach:
Distributed approach:
Pros:

Many nodes working simultaneously dramatically increases capacity

Nodes are placed where they are required for the local control
Easier automation, integration and flexibility
Independent (easier) debugging and maintenance of each part
Allows gradual expansion of the system

Cons:
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Harsh environment
Need for communication standards and interoperability

Julin Proenza. UIB. Mar 2009

Presentation Outline
1. Introduction
2. Components
3. Organization
1. General aspects
2. Types of Control

4. Reference Models. The CIM model

5. Design Approaches (centralized vs. distributed system)
6. Control Networks in AMSs
1.
2.
3.
4.
28

The OSI model point of view

The control hierarchy point of view
The device hierarchy point of view
Communication network architecture

Julin Proenza. UIB. Mar 2009

Control Networks in AMSs (1)

In a distributed control system the network is the

backbone and provides fundamental services

The use of networks in AMSs can be seen from many

different points of view:

29

The OSI model point of view

The control hierarchy point of view
The device hierarchy point of view

All these points of view lead together to a typical

communication network architecture

Julin Proenza. UIB. Mar 2009

Control Networks in AMSs (2)

The OSI model point of view:
Each layer provides specific services to the one above
Each layer adds some control information to the message
Node

Application

Common services for classes of applications

Presentation

Data semantics

Session

Remote actions

Transport

End-to-end communication control

Network

Routing, logical addressing

Data Link

Physical addressing, MAC, LLC

Physical

Topology, medium, bit-encoding

Physical interconnection medium

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Julin Proenza. UIB. Mar 2009

Control Networks in AMSs (3)

The OSI model point of view:
Each layer provides specific services to the one above
Each layer adds some control information to the message
Node

Application
Presentation
Session
Transport
Network
Data Link
Physical

- This approach causes large computation

and communication overheads
-Depending on the nodes involved the
communication has different requirements.
-Low cost
-Real-time
-High bandwidth
-Small vs large data
- For some requirements the stack
should be reduced
- The application layer is always important

Physical interconnection medium

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Julin Proenza. UIB. Mar 2009

Control Networks in AMSs (4)

The control hierarchy point of view:
Intra-level
& inter-level
comms

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Julin Proenza. UIB. Mar 2009

Control Networks in AMSs (5)

The device hierarchy point of view:
In the CIM model presented before there was a device
hierarchy that was implicit in the pyramid
At each level of this hierarchy a different kind of control is
carried out
Moreover, at each level, the communication requirements are
different
Real-time comms at the lowest levels vs. high bandwidth at the
highest ones
Smaller data at the lowest levels (sensor and actuator info)
Lower cost at the lowest levels (more and longer wires)

Furthermore, the different device levels must be connected

among them
Thus it is natural to have an architecture based on subnetworks
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Julin Proenza. UIB. Mar 2009

References
Source for these slides
J. R. Pimentel. Communication Networks for Manufacturing.
Prentice-Hall. 1990

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